CN111931370B - COMSOL-based ceramic insulator flash firing method - Google Patents
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- 239000000919 ceramic Substances 0.000 title claims abstract description 18
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Abstract
本发明利用仿真软件COMSOL，以氧化铝为样品，建立了闪烧的模型，获得了样品表面的温度分布，分析了电场强度和电流密度对样品致密度和样品尺寸的影响。有利于加深对闪烧的了解，对生产高性能陶瓷材料和高性能陶瓷绝缘子，提高我国高压输电线路的安全性和稳定性有着重要意义。
The invention uses the simulation software COMSOL, takes alumina as a sample, establishes a flash burning model, obtains the temperature distribution on the surface of the sample, and analyzes the influence of electric field intensity and current density on the sample density and sample size. It is beneficial to deepen the understanding of flash burning, and is of great significance to the production of high-performance ceramic materials and high-performance ceramic insulators, and to improve the safety and stability of high-voltage transmission lines in my country.
Description
技术领域technical field
本发明涉及陶瓷绝缘子制备的技术领域，特别是涉及了利用COMSOL仿真软件对制备陶瓷绝缘子的闪烧工艺进行了研究。The invention relates to the technical field of preparation of ceramic insulators, in particular to the research on the flash burning process for preparing ceramic insulators by using COMSOL simulation software.
背景技术Background technique
陶瓷绝缘子硬度高，熔点高，高温下具有良好的化学稳定性，良好的电气绝缘性和抗腐蚀性等，在电网中得到了广泛的应用。但是陶瓷绝缘子韧性差，脆性大，容易发生破碎，而且根据现场的运行来看，在运行过程中陶瓷绝缘子很容易发生沿面闪络。陶瓷绝缘子的性能和它的制造过程密切相关。传统的烧结工艺不仅需要很高的烧结温度和很长的烧结时间，消耗大量的能源，同时产生大量的温室气体，对环境十分不利。而且所制得样品的致密度不够高，会影响陶瓷材料的性能。为了解决上述问题，近些年来提出了许多新的技术。和其它新型技术相比，闪烧具有烧结温度低、速度快、保温时间短等特点，使得闪烧工艺得到了广泛的关注。Ceramic insulators have high hardness, high melting point, good chemical stability at high temperature, good electrical insulation and corrosion resistance, etc., and have been widely used in power grids. However, ceramic insulators have poor toughness, high brittleness, and are prone to breakage. According to the on-site operation, ceramic insulators are prone to surface flashover during operation. The performance of ceramic insulators is closely related to its manufacturing process. The traditional sintering process not only requires high sintering temperature and long sintering time, consumes a lot of energy, but also generates a large amount of greenhouse gases, which is very unfavorable to the environment. Moreover, the density of the prepared samples is not high enough, which will affect the properties of ceramic materials. In order to solve the above problems, many new technologies have been proposed in recent years. Compared with other new technologies, flash sintering has the characteristics of low sintering temperature, fast speed, and short holding time, which makes the flash sintering process receive extensive attention.
目前，国内外学者对于闪烧工艺参数和闪烧机理已有深刻研究，并且取得了大量阶段性成果。但是，学者们都是搭建闪烧的实验模型，去分析闪烧的过程。由于搭建的实验平台不同，所得的实验结果也没有达成一致。另外，由于闪烧过程的时间很短，不能准确地测量样品的一些参数，使得人们对闪烧机理的研究还存在争论。因此，通过建立闪烧的仿真模型，可以方便人们分析实验参数的影响，提高测量的准确性，希望可以推进闪烧机理的研究，对实际的实验情况先做出预测，减少实际实验花费的成本，有利于对实际实验结果进行判断，更快发现实际实验的误差或错误，还能避免一些危险的实际操作。At present, scholars at home and abroad have conducted in-depth research on the process parameters and mechanism of flash sintering, and have achieved a large number of staged results. However, scholars build experimental models of flash burning to analyze the process of flash burning. Due to the different experimental platforms built, the obtained experimental results did not reach a consensus. In addition, due to the short time of the flash-burning process, some parameters of the samples cannot be accurately measured, which makes the research on the flash-burning mechanism still in dispute. Therefore, by establishing a flash burning simulation model, it is convenient for people to analyze the influence of experimental parameters and improve the accuracy of the measurement. It is hoped that the research on the flash burning mechanism can be promoted, and the actual experimental situation can be predicted first, so as to reduce the cost of actual experiments. , which is helpful for judging the actual experimental results, discovering the errors or errors of the actual experiment faster, and avoiding some dangerous practical operations.
发明内容SUMMARY OF THE INVENTION
本发明的目的即在于，在COMSOL中建立了以氧化铝为样品的闪烧模型，详细地介绍了建立仿真模型的步骤，获得了稳定阶段样品的表面温度，讨论了电场强度和电流密度对样品产生的影响。研究成果可用于闪烧机理的研究，分析闪烧实验中电场强度、电流密度等因素对闪烧样品的影响，为生产高性能陶瓷材料和高性能陶瓷绝缘子开辟了一条新的路径，对提高我国高压输电线路的安全性和稳定性有着重要意义。The purpose of the present invention is to establish a flash burning model with alumina as a sample in COMSOL, introduce the steps of establishing the simulation model in detail, obtain the surface temperature of the sample in the stable stage, and discuss the effect of electric field intensity and current density on the sample. produced impact. The research results can be used to study the mechanism of flash burning, analyze the influence of electric field strength, current density and other factors on the flash burning samples in the flash burning experiment, which opens up a new path for the production of high-performance ceramic materials and high-performance ceramic insulators, and is conducive to improving my country's The safety and stability of high-voltage transmission lines are of great significance.
为实现上述目的，本发明采用如下技术方案，一种基于COMSOL的陶瓷绝缘子闪烧方法，具体步骤为：In order to achieve the above object, the present invention adopts the following technical scheme, a kind of ceramic insulator flash burning method based on COMSOL, the concrete steps are:
1、物理场的选择1. The choice of physical field
COMSOLMultiphysics是一款功能强大的多物理仿真软件，可以对多个领域的物理过程进行仿真。闪烧的过程涉及电学、热学等物理场，因此在COMSOL中选取了“焦耳热和热膨胀”物理场。“焦耳热和热膨胀”多物理接口包含了热、电和结构多物理效应的结合。其中，电介质中的电流分布、电场分布和电势分布可以在“电流”接口中进行计算。“固体力学”接口可以计算样品的应变、应力和位移。“固相传热”接口可以模拟模型中的传导传热、辐射传热和电流传热，接口中的温度作为“固体力学”界面的热载荷，会引起热膨胀。COMSOL Multiphysics is a powerful multiphysics simulation software that can simulate physical processes in multiple domains. The process of flash burning involves electrical, thermal and other physical fields, so the "Joule heat and thermal expansion" physical field is selected in COMSOL. The Joule Heating and Thermal Expansion multiphysics interface contains a combination of thermal, electrical, and structural multiphysics effects. Among them, the current distribution, electric field distribution, and potential distribution in the dielectric can be calculated in the "Current" interface. The Solid Mechanics interface calculates strain, stress, and displacement of the sample. The Heat Transfer in Solid Phase interface can simulate conduction, radiation, and current heat transfer in the model. The temperature in the interface acts as a thermal load on the Solid Mechanics interface, which causes thermal expansion.
2、几何模型的建立2. Establishment of geometric model
闪烧样品是一个简单三维几何体，因此建立了一个长方体用来模拟样品，这有助于我们更好地理解闪烧的过程，如图1所示。其中，长方体的长、宽、高分别为2.5μm、2.5μm、1μm。将沿着X轴方向的两个平面固定不动，并将样品的材料设置成氧化铝，周围的环境设置成空气。The flash burning sample is a simple three-dimensional geometry, so a cuboid is built to simulate the sample, which helps us better understand the flash burning process, as shown in Figure 1. The length, width and height of the cuboid are 2.5 μm, 2.5 μm, and 1 μm, respectively. The two planes along the X-axis are fixed, and the material of the sample is set to alumina, and the surrounding environment is set to air.
3、边界条件的施加3. The application of boundary conditions
这一步是COMSOL软件中最关键的一步，边界条件设置的是否合理直接决定了仿真是否能够成功。闪烧实验过程中，外部施加的变量有直流电压源和高温炉两个变量，所以在仿真过程中也需要添加这两个条件。This step is the most critical step in the COMSOL software. Whether the boundary conditions are set reasonably or not directly determines whether the simulation can be successful. During the flash burning experiment, the externally applied variables include the DC voltage source and the high temperature furnace, so these two conditions also need to be added in the simulation process.
实际过程中，氧化铝的电导率会随着温度的升高而升高，因此我们需要在“电流”接口下电流守恒的设置窗口中找到传导电流选项，将氧化铝电导率和温度的关系输入进去。这样在仿真过程中通过样品的电流会随着温度的升高而增大。将沿着X轴方向的两个平面，一个设置为电压的输入端，另外一个接地。在仿真过程中，可以改变电压值，也就相当于改变了电压强度，进而可以分析电压强度对样品的影响。将输入电压设置成0.0375V和0.075V，研究两种情况下的闪烧过程。In the actual process, the conductivity of alumina will increase with the increase of temperature, so we need to find the conduction current option in the setting window of current conservation under the "Current" interface, and input the relationship between alumina conductivity and temperature go in. This way the current through the sample increases with temperature during the simulation. Set the two planes along the X-axis, one for the voltage input and the other for ground. In the simulation process, the voltage value can be changed, which is equivalent to changing the voltage intensity, and then the influence of the voltage intensity on the sample can be analyzed. Set the input voltage to 0.0375V and 0.075V to study the flash-in process in both cases.
在模型开发器窗口的固体传热节点下，将样品的初始温度设置为800K。这样做的目的是提供闪烧的初始温度，使整个几何模型都保持在这个温度下。为了模拟闪烧实验中样品可以和对流空气进行冷却，设置了一个传热系数h＝5W/(m2·K)的热通量边界条件。In the Model Builder window, under the Heat Transfer in Solids node, set the initial temperature of the sample to 800K. The purpose of this is to provide an initial temperature for the flash burn, at which the entire geometry is maintained. In order to simulate that the sample can be cooled with convective air in the flash burning experiment, a heat flux boundary condition with a heat transfer coefficient h=5W/(m2·K) is set.
4、网格的划分4. Grid division
几何模型的网格直接决定了模型的求解方式，不同的网格划分方式会造成模型求解时间的不同、求解精度的不同和计算仿真模型所需内存量的不同。网格划分的越细，求解精度越高，所得的仿真结果也会更加接近实际值。因此，针对不同的几何模型和不同的问题，需要选择合适的网格划分方式。综合考虑仿真的精确度和仿真时间，选择了使用自有四面体网格进行划分，并在网格的大小设置栏中选择较细化。几何模型的网格划分图如图2所示。The grid of the geometric model directly determines the solution method of the model. Different grid division methods will result in different model solution time, different solution accuracy and different memory required for computing the simulation model. The finer the mesh division, the higher the solution accuracy, and the obtained simulation results will be closer to the actual value. Therefore, for different geometric models and different problems, it is necessary to select an appropriate meshing method. Considering the simulation accuracy and simulation time comprehensively, we choose to use our own tetrahedral mesh for division, and select finer mesh in the mesh size setting column. The meshing diagram of the geometric model is shown in Figure 2.
本发明使用COMSOL对闪烧工艺制备陶瓷绝缘子进行了仿真，对保障输电线路的稳定性、可靠性具有重要意义，其具体的有益效果包括：The invention uses COMSOL to simulate the preparation of the ceramic insulator by the flash burning process, which is of great significance for ensuring the stability and reliability of the transmission line, and its specific beneficial effects include:
1、虽然闪烧已经被应用且生产了一系列陶瓷材料，但是温度测量的不确定性的原因限制了对闪烧机制的理解和研究，温度的急剧变化与难以测量极大地限制了闪烧机理的探索。仿真获得了稳定阶段闪烧样品的表面温度，有助于闪烧机理的探索，为学者提出的闪烧机理提供支撑。1. Although flash sintering has been applied and a series of ceramic materials have been produced, the reason for the uncertainty of temperature measurement limits the understanding and research of the flash sintering mechanism. exploration. The surface temperature of the flash-burning samples in the stable stage is obtained by simulation, which is helpful for the exploration of the flash-burning mechanism and provides support for the flash-burning mechanism proposed by scholars.
2、利用搭建的陶瓷绝缘子的闪烧模型，分析了电压强度和电流密度对样品致密度和样品尺寸的影响，研究了电压强度和电流密度之间的关系，验证了闪烧确实可以提高样品的致密度，为闪烧实验中电压强度、电流密度和温度的选取具有指导意义。2. Using the flash burning model of the built ceramic insulator, the influence of voltage intensity and current density on the sample density and sample size was analyzed, and the relationship between voltage intensity and current density was studied, and it was verified that flash burning can indeed improve the sample's performance. The density has guiding significance for the selection of voltage intensity, current density and temperature in the flash burning experiment.
附图说明Description of drawings
通过阅读下文优选实施方式的详细描述，各种其他的优点和益处对于本领域普通技术人员将变得清楚明了。附图仅用于示出优选实施方式的目的，而并不认为是对本发明的限制。而且在整个附图中，用相同的参考符号表示相同的部件。在附图中：Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are for the purpose of illustrating preferred embodiments only and are not to be considered limiting of the invention. Also, the same components are denoted by the same reference numerals throughout the drawings. In the attached image:
图1为闪烧仿真的几何模型图；Fig. 1 is the geometric model diagram of flash burning simulation;
图2为闪烧仿真的几何模型网格划分图；Fig. 2 is the geometric model meshing diagram of flash burning simulation;
图3为闪烧样品表面温度分布图；Fig. 3 is the surface temperature distribution diagram of the flash burning sample;
图4为不同电场强度时电流密度随时间的变化图；Figure 4 is a graph showing the variation of current density with time under different electric field strengths;
图5为不同电压强度下闪烧样品表面位移图；Figure 5 is the surface displacement diagram of the flash-fired sample under different voltage intensities;
图6为电流密度为1.74A/m2时闪烧样品表面位移图。Figure 6 is the surface displacement diagram of the flash-fired sample when the current density is 1.74A/m2.
具体实施方式Detailed ways
下面将参照附图更详细地描述本公开的示例性实施方式。虽然附图中显示了本公开的示例性实施方式，然而应当理解，可以以各种形式实现本公开而不应被这里阐述的实施方式所限制。相反，提供这些实施方式是为了能够更透彻地理解本公开，并且能够将本公开的范围完整的传达给本领域的技术人员。Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided so that the present disclosure will be more thoroughly understood, and will fully convey the scope of the present disclosure to those skilled in the art.
1、闪烧样品表面温度分析：1. Surface temperature analysis of flash samples:
改变直流电压值，当电场强度为300V/cm时，稳定阶段闪烧样品的表面温度分布图如图3所示。可以发现，样品表面存在温度梯度，而且样品表面许多部位的温度均大于800K。正是因为样品表面温度的升高，达到内部空隙体积减少，颗粒间距缩短，样品密度增大，更加快速地形成稳定的晶体结构。这就能很好地解释了闪烧的时间很短且能快速致密化的原因。Change the DC voltage value, when the electric field strength is 300V/cm, the surface temperature distribution of the flash burning sample in the stable stage is shown in Figure 3. It can be found that there is a temperature gradient on the surface of the sample, and the temperature of many parts of the sample surface is greater than 800K. It is precisely because of the increase of the surface temperature of the sample that the internal void volume is reduced, the particle spacing is shortened, the density of the sample is increased, and a stable crystal structure is formed more quickly. This is a good explanation for the short flash burning time and rapid densification.
样品表面温度的升高可以用焦耳热效应来解释。样品在电流的作用下会产生焦耳热，焦耳热产生大量的热量会使周围的温度升高。因为氧化铝的电导率和温度是正比例关系，所以温度的升高会使得样品的电导率增大。当电场强度不变时，根据，电导率增大也就是电阻变小，造成电能的热效应增大，温度的升高。这个过程是一个正反馈，会使得样品的温度不断地升高。如果不将电流密度进行限制，样品的温度将会无止境的增加下去。The increase in sample surface temperature can be explained by the Joule heating effect. The sample will generate Joule heat under the action of the current, and the Joule heat will generate a lot of heat and will increase the surrounding temperature. Since the conductivity of alumina is proportional to temperature, an increase in temperature increases the conductivity of the sample. When the electric field strength is constant, according to the fact that the electrical conductivity increases, that is, the resistance decreases, resulting in an increase in the thermal effect of the electric energy and an increase in the temperature. This process is a positive feedback, which will continuously increase the temperature of the sample. If the current density is not limited, the temperature of the sample will increase indefinitely.
2、电场强度的影响：2. The influence of electric field strength:
当施加的直流电压为0.075V即电场强度为300V/cm时，电流密度随时间的变化图如图4(a)所示。根据仿真2结果图，可以将闪烧分为三个阶段：0-0.25s、0.25-0.5s、0.5s以后。在第一阶段中，电场强度保持不变，电流密度和功率缓慢增加，这个阶段称为孕育阶段，是发生闪烧之前的一个阶段。在第二个阶段中由于焦耳热效应的作用，样品的温度不断升高，达到了闪烧的阈值，因此样品发生闪烧，样品快速收缩并伴随有电致发光现象。所以，第二个阶段叫做闪烧的发生阶段，这一阶段最明显的现象是电流密度快速地增加。当电流密度达到临界值时便保持不变，进入第三阶段。第三个阶段称为闪烧的保温阶段，电流密度不再发生变化，样品的电阻率也保持不变，直到冷却到室温。When the applied DC voltage is 0.075V, that is, the electric field strength is 300V/cm, the change of current density with time is shown in Fig. 4(a). According to the results of
当电场强度为150V/cm时，通过样品的电流密度随时间的变化图如图4(b)所示。通过对比图4(a)和图4(b)，我们可以发现电场强度会对孕育时间产生影响，电场强度越大，孕育时间越短。当改变输入的直流电压值时，我们发现样品表面的位移图都是一样的，如图5所示。根据这个结果，可以得出：电场强度不会对样品的致密度产生影响。When the electric field strength is 150 V/cm, the variation of current density through the sample with time is shown in Fig. 4(b). By comparing Fig. 4(a) and Fig. 4(b), we can find that the electric field strength will have an effect on the incubation time. The greater the electric field strength, the shorter the incubation time. When changing the input DC voltage value, we found that the displacement maps of the sample surface are all the same, as shown in Figure 5. According to this result, it can be concluded that the electric field strength has no effect on the density of the sample.
因此，电场强度不会影响样品致密度的变化，它只会造成闪烧孕育阶段的时间的变化。Therefore, the electric field strength does not affect the variation of the sample density, it only causes the variation of the flash incubation time.
3、电流密度的影响：3. The influence of current density:
电流密度是一个很重要的因素，因为它直接和样品的温度相关联。电流密度越大，样品的温度越高。将电流密度设置为1.74A/m2时，样品表面的位移如图6所示。通过图5和图6的对比，我们得到电流密度的不同会导致样品表面位移的不同。换句话说电流密度越大，会使样品的致密度得到增加，但是不可避免的也会造成样品尺寸的增大。Current density is an important factor because it is directly related to the temperature of the sample. The higher the current density, the higher the temperature of the sample. When the current density is set to 1.74 A /m, the displacement of the sample surface is shown in Fig. 6. Through the comparison of Fig. 5 and Fig. 6, we get that the difference of current density will lead to the difference of the surface displacement of the sample. In other words, the higher the current density, the higher the density of the sample, but the inevitable increase in the size of the sample.
当组成陶瓷绝缘子的化学成分相同时，陶瓷的微观结构是影响陶瓷性能的主要因素。为了提高陶瓷绝缘子的绝缘性能，通过闪烧工艺制备绝缘子可以很好地提升绝缘子的性能。闪烧过程中，我们可以通过控制电压强度调整孕育时间，通过控制电流密度调整样品的致密度和样品的尺寸。When the chemical composition of the ceramic insulator is the same, the microstructure of the ceramic is the main factor affecting the performance of the ceramic. In order to improve the insulation performance of ceramic insulators, the performance of insulators can be well improved by preparing insulators by flash burning process. During the flash burning process, we can adjust the incubation time by controlling the voltage intensity, and adjust the density and size of the sample by controlling the current density.
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以所述权利要求的保护范围为准。The above description is only a preferred embodiment of the present invention, but the protection scope of the present invention is not limited to this. Substitutions should be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.
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